Key duplication machine

ABSTRACT

Apparatus, methods, and other embodiments associated with a key duplication machine are described. In one embodiment, an assembly for duplicating a master key includes an optical imaging device, a logic, a clamping assembly, and a cutting member. The optical imaging device is capable of capturing an optical image of at least a portion of the master key. The logic is capable of determining a key pattern of the master key from the optical image of the master key. The clamping assembly is capable of clamping a key blank and the cutting member is capable of cutting a key pattern into said key blank.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of U.S. patent applicationSer. No. 13/015,982 titled “KEY DUPLICATION MACHINE,” filed on Jan. 28,2011, which is a continuation of U.S. patent application Ser. No.13/006,714, now U.S. Pat. No. 8,128,322, titled “KEY DUPLICATIONMACHINE,” filed on Jan. 14, 2011, which is a continuation of U.S. patentapplication Ser. No. 11/656,925, now U.S. Pat. No. 7,891,919, titled“KEY DUPLICATION MACHINE,” filed on Jan. 23, 2007, which claims thebenefit of U.S. Provisional Patent Application No. 60/761,293, titled“KEY DUPLICATION MACHINE,” filed Jan. 23, 2006, each of which are herebyincorporated in their entirety.

FIELD OF INVENTION

This invention relates generally to apparatus and methods forduplicating keys, and more specifically, this invention relates toapparatus and methods for cutting duplicate keys based on a capturedimage of a master key.

BACKGROUND

Key duplication and key cutting machines are designed to reproduce a keypattern of a master key onto a key blank. Prior art key duplication andkey cutting machines typically determine the key pattern of a master keyby mechanically engaging the key pattern of a master key with a stylus,tracer bar, or other such mechanical member. For example, prior art keyduplication machines typically comprise a pair of clamps or vise gripsmounted on a carriage. A master key, having a key pattern, is placed ina first clamp. A key blank, manually selected by the machine operator,is placed in a second clamp, which is normally positioned adjacent tothe first clamp. The stylus is placed in contact with the key pattern ofthe master key. A cutting wheel is placed in contact with an edge of thekey blank, into which the key pattern of the master key is to beduplicated. The stylus and cutting wheel are coupled such that themovement of the cutting wheel is synchronized with and controlled by themovement of the stylus.

The carriage is arranged such that the carriage may be moved pivotallyand linearly along a longitudinal supporting shaft that is generallyparallel to the blades of the master key and key blank. The carriage istypically moved manually along the shaft, causing the stylus to movealong the key pattern of the master key. As the stylus moves along thekey pattern of the master key to trace the key pattern, the cuttingwheel moves along the blade of the key blank. The coupling of the stylusand cutting wheel controls the movement of the cutting wheel and cuts aduplicate key pattern into the key blank. Once the cutting process iscompleted, the newly duplicated key may be removed from the clamp andbuffed on a buffing wheel or swiped across a wire brush to remove anyburrs.

In the prior art process described, the key cutting machine operatormanually selects the key blank. It is of great importance that the keypattern of a master key be copied onto an appropriate key blank havingthe same key blade and grooves. There are numerous key blanks, and manyare not readily distinguishable from each other. Identifying the correctkey blank for use in duplication often requires visually examination ofa plurality of key blanks, where differences between key blanks may bevery subtle, significantly increasing the level of difficulty inidentifying the proper key blank. All too often, businesses that offerkey cutting services are not staffed by experienced locksmiths capableof consistently and accurately identifying the proper key blank to beused. Instead, an employee is shown how to “eyeball” what is thought tobe the correct blank and then cut a duplicate key at the substantialrisk of the key working improperly.

Once a key blank is manually chosen by the operator, that key blank goesthrough the cutting process. If a mistake is made in the manualselection of a key blank, the entire process of manually identifying thebest key blank and mechanically cutting the key must begin again. Often,such errors are not identified until after the customer leaves thestore, thus resulting in frustration with the retailer due to anunsuccessful key cut.

Although prior art key duplication machines and processes are wellestablished and widely utilized, such machines and processes produce arelatively high scrap rate, overly rely on the experience and judgmentof machine operators, and may not allow for evaluation of the accuracyof a duplicate key without the duplicate key being tested in itsassociated lock. Due to these and other limitations of the prior art,the art field is constantly striving to improve cut accuracy, cutquality, and ease of use of key duplication machines and processes.Improvements to key duplication machines and processes that enhance theaccuracy and quality of a duplicate key or produce more user-friendlymachines are well received in the key duplication industry.

A general goal of the industry is to develop key duplication machinesand processes that are so user-friendly that a customer or generalconsumer may duplicate a key with minimal instructions and minimalknowledge of keys. Therefore, improvements in machines and processes forcutting duplicate keys that simplify the cutting process or improve theaccuracy of key blank identification are greatly desired. Further, theindustry constantly strives for less expensive, easier to assemble, andeasier to maintain machines. Should newly developed key duplicationmachines or processes achieve any of these objectives, it would be asignificant improvement over the expensive and often difficult to usekey cutting machines currently known in the field.

SUMMARY OF INVENTION

Apparatus, methods, and other embodiments associated with a keyduplication machine are described. In one embodiment, an assembly forduplicating a master key includes an optical imaging device, a logic, aclamping assembly, and a cutting member. The optical imaging device iscapable of capturing an optical image of at least a portion of themaster key. The logic is capable of determining a key pattern of themaster key from the optical image of the master key. The clampingassembly is capable of clamping a key blank and the cutting member iscapable of cutting a key pattern into said key blank.

In another embodiment, a method for duplicating a master key includescapturing an optical image of at least a portion of the master key;providing a logic to determine a key pattern of the master key from theoptical image of the master key; securing a key blank; and cutting a keypattern into the key blank.

DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which are incorporated in and constitute apart of this specification, embodiments of the invention areillustrated, which, together with a general description of the inventiongiven above, and the detailed description given below serve toillustrate the principles of this invention. The drawings and detaileddescription are not intended to and do not limit the scope of theinvention or the claims in any way. Instead, the drawings and detaileddescription only describe embodiments of the invention, and otherembodiments of the invention not described are encompassed by theclaims.

FIG. 1 is perspective view of an exemplary embodiment of a keyduplication machine in accordance with the present invention;

FIG. 2 is a front view of the key duplication machine of FIG. 1;

FIG. 3 is a side view of the key duplication machine of FIG. 1;

FIG. 4A is a plan view of a master key;

FIG. 4B is a plan view of a key blank;

FIG. 5 is a perspective view of a key secured in the slot of the keyduplication machine of FIG. 1;

FIG. 6 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 7 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 8 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 9 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 10 is a plan view of a key blank positioned between positionerfingers of the key duplication machine of FIG. 1;

FIG. 11 is a perspective view of a cutting wheel and positioner fingerof the key duplication machine of FIG. 1;

FIG. 12 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 13 is a perspective view of a top clamp member of the keyduplication machine of FIG. 1;

FIG. 14 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 15 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 16 is a front view of a shavings drawer of the key duplicationmachine of FIG. 1;

FIG. 17 is a rear view of a shavings drawer of the key duplicationmachine of FIG. 1;

FIG. 18 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 19 is a partial perspective view of the interior of the keyduplication machine of FIG. 1;

FIG. 20 is an exploded view of the key duplication machine of FIG. 1;

FIG. 21 is an exploded view of the key duplication machine of FIG. 1;

FIG. 22 is a screen shot of a user interface for use with the keyduplication machine of claim 1;

FIG. 23 is a screen shot of a user interface for use with the keyduplication machine of claim 1;

FIG. 24 is a screen shot of a user interface for use with the keyduplication machine of claim 1;

FIG. 25 is a screen shot of a user interface for use with the keyduplication machine of claim 1; and

FIG. 26 is a screen shot of a user interface for use with the keyduplication machine of claim 1.

FIG. 27 is a front view of an embodiment of a mechanical door panel.

FIG. 28 is a rear view of an embodiment of a mechanical door panel.

FIG. 29 is a perspective view of a lower door gripper

FIG. 30 is a perspective view of an upper door gripper.

FIG. 31 is a front view of a movable door.

DETAILED DESCRIPTION OF THE INVENTION

The Detailed Description of the Invention merely describes embodimentsof the invention and is not intended to limit the scope of the claims inany way. Indeed, the invention as described by the claims is broaderthan and unlimited by the preferred embodiments, and the terms in theclaims have their full ordinary meaning.

As described herein, apparatus and methods can be designed to produceaccurate and reliable duplicates of master keys. In one embodiment, theduplication of a master key is facilitated by the capture of an opticalimage of a profile or silhouette of the master key, including the keypattern of the master key, and the capture of a profile or silhouette ofa key blank. As will be further described herein, the captured imagesmay be analyzed by logic to determine the proper key blank to be usedfor a duplicate key, validate the selection of the proper key blank,facilitate the accurate cutting of the key pattern of the master keyinto the key blank, and validate the accuracy of the key pattern cutinto the key blank. The apparatus and methods may further facilitate thecutting of a substantial variety of key types, such as single-sidedkeys, double-sided keys, sidewinder keys, house keys, automobile keys,commercial keys, and the like. The analysis of images by logic mayinclude, for example, the logic storing images, storing data,quantifying physical measurements based on the image, retrievingreferencing data contained in a database, and the like.

As used herein, the term “logic” includes but is not limited tohardware, firmware, software and/or combinations of each to perform afunction(s) or an action(s), and/or to cause a function or action fromanother logic, method, and/or system. For example, based on a desiredapplication or needs, logic may include a software controlledmicroprocessor, discrete logic like an application specific integratedcircuit (ASIC), an analog circuit, a digital circuit, a programmed logicdevice, a memory device containing instructions, or the like. Logic mayinclude one or more gates, combinations of gates, or other circuitcomponents. Logic may also be fully embodied as software. Where multiplelogical logics are described, it may be possible to incorporate themultiple logical logics into one physical logic. Similarly, where asingle logical logic is described, it may be possible to distribute thatsingle logical logic between multiple physical logics. In addition, asused herein, the term “database” includes a physical and/or logicalentity that can store data. A database may be, for example, atraditional database, a table, a file, a list, a queue, a heap, amemory, a register, and so on. A database may reside in one logicaland/or physical entity and/or may be distributed between two or morelogical and/or physical entities.

Optionally, the apparatus and methods described herein may accept inputfrom a user or operator of a key duplication machine and may provideoutput to the user or operator of the machine to further facilitate keyduplication. For example, the apparatus may include a user interface,such as monitor, touch screen, or other such device, through which auser may enter information and information may be displayed to the user.

In an embodiment, a method of using the key duplication machinecomprises the steps of inserting a master key into the machine such thatthe blade of the master key is within an imaging zone of the machine;capturing an image of the key pattern of the master key; utilizing logicto analyze the captured image; comparing the captured image with data onkey blanks contained in a database; determining the proper key blank forduplicating the master key; outputting information regarding the properkey blank to the user; removing the master key from the machine;retrieving and inserting the proper key blank into the machine such thatthe blade of the key blank is within the imaging zone of the machine;capturing an image of the key blank; using logic to analyze the image ofthe key blank and validating that the key blank is proper; aligning thekey blank; moving the key blank to a cutting zone of the machine;cutting the key pattern of the master key into the key blank; moving thenewly-cut duplicate key to the imaging zone of the machine; capturing animage of the duplicate key; using logic to analyze the image of theduplicate key; compare the analysis of the image of the master key withthe analysis of the image of the duplicate key to validate the accuracyof the key pattern cut into the duplicate key; removing the duplicatekey from the machine; and de-burring the duplicate key.

An exemplary embodiment of a key duplication machine 10 is illustratedin the accompanying Figures. The key duplication machine 10 as describedherein has numerous features or improvements, each of which are believedto be independently novel. Therefore, while embodiments of the presentinvention are described as utilizing each of these novel features orimprovements in the aggregate, nothing in the present description shouldbe interpreted as requiring an embodiment to include or exclude any ofthe particular improvements described herein. In addition, the keyduplication machine 10 described herein incorporates a key blankidentification system and a key cutting system into a single apparatus.However, it should be understood that either system could be usedindividually or used together. Nothing in this description should beinterpreted to limit novel features of each individual system as usedalone or in an integrated unit. Therefore, as described herein as anintegrated system, a master key is imaged and compared with other keyblanks to determine the appropriate key blank to be used, while alsoutilizing the master key image to provide key pattern information to becut into the key blank.

FIGS. 4A and 4B illustrate a common master key 22 and key blank 24.While it is known that numerous types of keys are used in the keyindustry, for simplicity the master key 22 illustrated in FIG. 4A is anexemplary house key, and the key blank 22 illustrated in FIG. 4B is aexemplary key blank 24 for the house key 22. Both the master key 22 andkey blank 24 typically include a head 26 having a bow 28, a shoulder 30,a blade 32, and a keyway groove 34. The keyway groove 34 is typically anarrow, milled-out area along the length of the blade 32 that allows theblade 32 to bypass the wards in a keyway. Such keyway grooves 34 mayalready be cut into the key blank 24 to simplify the key cuttingoperation. Therefore, when duplicating a master key 22, a key blank 24must include a keyway groove 34 that is either identical to or similarto the master key 22. The master key 22 includes a key pattern 36, whichis a model for any key pattern cut into the key blank 24 in duplicatingthe master key 22. As used herein, master key refers to any key that hasa key pattern, whether an original key purchased with a lock andfabricated by the manufacturer of the lock or a subsequent duplicationof the original key. The reference to a key as a master key indicatesthat the key serves as a model from which to cut a duplicate key toperform the same unlocking function as the master key.

With reference to FIGS. 1 through 3, an assembled key duplicationmachine 10 is illustrated. The machine 10 includes an outer shell 12,comprising a number of panels arranged to enclose and protect internalcomponents, mechanisms, and systems of the key duplication machine 10.The machine 10 further includes a door clamp 14, which is biased againsta base 16 with a biasing member (not shown). The door clamp 14 may bebiased against the base 16 by any biasing member such as, for example,an extension or compression coil spring, a torsion spring, acounterweight, or the like. The door clamp 14 may be raised against thebiasing force by a handle 18.

The combination of the door clamp 14, base 16, handle 18, and biasingmember forms a retention mechanism 19 for retaining or securing a masterkey 22 or key blank 24. As illustrated in FIG. 5, the door clamp 14 andthe base 16 form a slot 20 that may be utilized to retain or secure amaster key 22 or key blank 24 such that the blade 32 of the key 22 and24 is located within the machine 10. The force placed on the key 22 and24 in the slot 20 is sufficient to retain or hold the key 22 and 24 inplace but also allows some movement of the key 22 and 24 to facilitateproper alignment of the key 22 and 24.

As will be further described, the blade 32 of a key 22 and 24 may bepositioned within the machine 10 such that an image of the blade 32 maybe captured. In addition, the blade 32 of a key blank 24 may bepositioned within the machine 10 such that the blade 32 is exposed toclamps and cutters. The clamps are arranged to selectively rigidlysecure the key blank 24, and the cutters are arranged to selectively cuta key pattern into the blade 32 of the key blank 24 when the key blank24 is rigidly secured in the clamps.

In an embodiment, the key 22 and 24 may be positioned with a first sideof the blade 32 facing upward, or the key 22 and 24 may be rotated 180degrees and positioned with the first surface of the blade 32 positioneddownward. As will be further described, in such an embodiment, suchvariable orientation or registration of the key 22 and 24 does notaffect the subsequent imaging, positioning or cutting of a key 22 and24. The key duplication machine 10 may be arranged such that logic usedto analyze images and control the movement, alignment, and cutting ofkeys 22 and 24 may detect the orientation or registration of the key 22and 24 and account for such orientation or registration during theduplication of a master key 22 so that the proper key cuts are maderegardless of the positioning of the key blank 24 so as to promote userfriendliness and speed of duplication.

The door clamp 14, base 16, handle 18, and slot 20 are located on aretention mechanism panel 21. The panel 21 is arranged such that thepanel 21 may slide to the left and right, with respect to FIG. 2. Aswill be further described, such movement allows the machine 10 to movethe blade 32 of a key blank 24 between an imaging zone, where an imageof the blade 32 may be captured, and a cutting zone, where a key pattern36 may be cut into a key blank 24.

The key duplication machine 10 includes a table 38 located below theslot 20. The table 38 is positioned such that when a master key 22 issecured in the slot 20, the table 38 holds additional keys on a key ringso that the user does not have to remove the master key 22 from its keyring for the purposes of duplication. A touch-screen monitor 40 isincorporated into the machine 10, through which a user may enterinformation and information may be displayed to the user. In addition, ametal shavings drawer 42 is provided beneath the internal key cuttingmechanisms to catch metal shavings generated during the cutting of keys.The shavings drawer 42 may be removed from the machine 10 to facilitatethe disposal of collected shavings. For convenience, a de-burring slot44 is provided. The slot 44 leads to a burr-cleaning member such as awheel, square brush, or the like, to clean and de-burr newly cut keys.

Optionally, a vacuum system (not shown) may be incorporated into themachine 10 to capture key cutting shavings as they are generated and toassist in cleaning the work area after key cutting operations. Such avacuum system may be attached to the machine 10 in the vicinity of thecutting operation or in or near a catch basin. Such an exemplary systemis described in U.S. patent application Ser. No. 10/970,844, titled KEYCUTTING MACHINE, filed on Oct. 20, 2004, and commonly owned by thepresent assignee. The Ser. No. 10/970,844 patent application is herebyexpressly incorporated by reference in its entirety. The Ser. No.10/970,844 application describes a removable vacuum tube capable ofcapturing key cutting shavings and assisting in cleaning the work areaafter the key cutting operation. It will be clear to those skilled inthe art that such a vacuum system could be incorporated into the presentapparatus and attached in the vicinity of the cutting operation or in ornear the catch basin.

As will be further described, during the process of duplicating orcutting a key, internal components, mechanisms, and systems of the keyduplication machine 10 experience motion and movement relative to othercomponents of the machine 10. To facilitate the description of suchmotion and movements, reference will be made to movements relative to anX-axis, Y-axis, and Z-axis. The orientations of these axes are shown inFIGS. 1 through 3. When motion or movement is described herein as“moving along the X-axis,” for example, this description includes motionalong any axis parallel to the X-axis shown in FIGS. 1 through 3.Movements along the X-axis are generally between the front and back ofthe machine 10, movements along the Y-axis are generally between theleft side and right side of the machine 10, and movements along theZ-axis are generally between the top and bottom of the machine 10. Aswill be understood by those skilled in the art, descriptions of motionor movement along an axis are not intended to be exactly and preciselyalong or parallel to such an axis. Movement and motion that isapproximately or roughly along an axis or parallel to an axis areincluded in the description of motion or movement along an axis. The useof “along an axis” or “about an axis” are intended to simplify a generaldescription of the apparatus and methods described herein and notintended to limit the scope or understanding of such apparatus andmethods.

FIGS. 6 though 21 illustrate exemplary internal components, mechanisms,and systems of the key duplication machine 10 and will be referenced indescribing methods for using the machine 10 to form duplicate keys frommaster keys 22.

Referring again to FIG. 5, a master key 22 or key blank 24 may be placedand retained in the slot 20 in the retention mechanism panel 21 suchthat the blade 32 is positioned within the machine 10 and in the imagingzone. As best seen in FIG. 6, an optical imaging device 50 is mountedwithin the machine 10 and positioned such that it captures an opticalimage of a key 22 and 24 secured in the slot 20. The image of the key 22and 24 may generally include the blade 32 of the key 22 and 24, the keyshoulder 30, and at least a portion of the head 26. As generally usedherein, the imaging area is an area that is below (along the Z-axis) theoptical imaging device 50. The optical imaging device 50 is generallypositioned above the key 22 and 24 and directed downward such that asilhouette of the key 22 and 24, including the blade 32 of the key 22and 24, may be captured.

In one embodiment, the optical imaging device 50 is a camera, and theimage captured is a photographic image. In an embodiment, the camera 50is a digital camera, and the image captured is a digital image. Adigital image may be stored in file form or in data form and may beanalyzed by logic. As best seen in FIG. 6, a tube 51 (shown incross-section) may extend downward from the imaging device 50 towardsthe key 22 and 24. Such a tube 51 may facilitate the channeling of lightto the camera and result in a high quality captured image.

To enhance an image captured by the optical imaging device 50, themachine 10 includes a system for providing backlighting to the key 22and 24. As best seen in FIG. 7, a lighting panel 52, reflector plate 54,and a blocking plate 56 cooperate to provide backlighting to the key 22and 24. The lighting panel 52 emits light, which is reflected off thereflector plate 54 and directed towards the key 22 and 24. A surface 58of the reflector plate 54 is coated or otherwise treated to disperse anddiffuse light emitting from the lighting panel 52. This dispersion anddiffusion of light creates a backlighting environment that enhancescaptured images of the key 22 and 24. The coating or treatment of thesurface 58 of the reflector panel 54 may be any coating or treatmentthat sufficiently disperses and diffuses light. For example, the surface58 may be coated with a gritty substance, such as sandpaper; the surface58 may be painted; the surface 58 may be machined or otherwise treatedto roughen the surface 58; or the surface 58 may include a pattern thatdisperses and diffuses light. The reflector plate 54 may be arranged ata relatively steep angle, as best seen in FIG. 7, to decrease thelikelihood that shavings from the cutting of keys may fall onto andstick to the surface 58 of the reflector plate 54. Such an angle makesit likely that shavings falling onto the surface 58 will slide off thesurface 58 and settle into the shavings drawer 42. In an embodiment, anytreatment or coating applied to the surface 58 of the reflector plate 54is selected to match the color and reflectivity of any buildup of dustthat may accumulate onto the surface 58 due to the cutting of keys abovethe reflection plate 54.

The lighting panel 52 may include any type of light-emitting devicessuch as, for example, light bulbs, light emitting diodes (LED), liquidcrystal displays (LCD), and the like. In an embodiment, the light panel52 comprises a matrix of evenly spaced LEDs. Alternatively, LEDs may beunevenly spaced so as to create more favorable light dispersion anddiffusion. In an embodiment, the light emitted from the lighting panel52 may be in the red spectrum, which may, under certain circumstances,create crisper images of a key silhouette. As will be understood bythose skilled in the art, other types of backlighting systems mayinclude directing light on the shavings or an object in the shavingsdrawer 42. Any particular configuration that provides well-dispersed anddiffused light appropriate for backlighting is contemplated andincorporated herein. Alternatively, front lighting or providing lightdirectly to the key 22 and 24 may also be used when capturing an imageof the key 22 and 24.

The logic may be arranged to analyze the backlighting and the resultingquality of a captured image. Based on such analysis, the backlightingmay be adjusted, such as in direction or in intensity, to improvesubsequent captured images. In addition, the positioning of the lightingpanel 52, reflector plate 54, and a blocking plate 56 may also beadjusted to improve subsequent captured images.

The apparatus as described may be utilized to capture the image of theblade 32 of a master key 22, including the key pattern 36. Such acaptured image may be analyzed by logic to quantify and specificallydefine the key pattern 36 of the master key. Such analysis may includequantifying and defining the depth, angle, and position of each tooth inthe key pattern 36; determining whether there is a key pattern 36 on oneside of the key 22 (a single-sided key) or on both sides of the key 22(a double-sided key); determining precisely where along the blade 32 thekey pattern 36 begins and ends; and the like. In addition, surfacefeatures of the blade 32, such as the presence, length, and width of akey groove 34, may be determined. In one embodiment, surface features ofthe blade 32 may be determined by positioning the optical imaging device50 to an angle with respect to the surface of the blade 32. As will befurther described, such information may be stored by the logic forsubsequent use in selecting a key blank 24, precisely cutting a keypattern into a key blank 24 and in comparing the key pattern cut intothe key blank 24 and the key pattern 36 of the master key 22.

The captured image of the blade 32 of the master key 22 may also be usedto specifically determine the proper key blank 24 to use whenduplicating the master key 22. The captured image may be analyzed usinglogic to quantify and specifically define features of the master keyblade 32 such as, for example, the size and shape of the shoulder 30,the length and width of the blade 32, whether the master key 22 issingle-sided or double-sided, whether the blade 32 includes any steps orgrooves, and the like. To facilitate the identification of a proper keyblank 24, the logic may compare the quantified and defined features ofthe master key 22 with data in a database regarding known key blanks 24.Such a database may include data on the physical dimensions of known keyblanks 24, and the logic may make direct comparisons between physicaldimensions of known key blanks 24 and the features of the master key 22as determined from the captured image. Such comparisons may lead to thedetermination and selection of the proper key blank 24 for the masterkey 22.

Optionally, additional imaging of the master key 22 may be performed todetermine or quantify surface features of the master key 22 such as, forexample, the keyway groove 34. Such surface features may assist innarrowing or choosing the proper key blank 24. Such imaging may beperformed by providing a ring of structured light about the key blade 32and an optical imaging device to record a tip view or cross-sectionalview of the key 24, performing a laser scan across the key blade 32 toidentify the width and spacing of a keyway groove 34, or projecting ashadow across the surface of the blade 32 to measure the variations inshadow contour related to surface area contour.

With regard to a laser scan of the key blade 32, a dot scan may beutilized using a single laser dot that may be moved continuously along apath, projected at certain points along a path, or utilized withmultiple laser dot scans in numerous types of configurations to acquirethe necessary information. It should be clear that such a scan couldread one or both sides of a key 22. Information on the groove 34 maylikewise be analyzed and compared by the logic to groove informationstored in the database related to known key blanks 24. Therefore, basedupon the master key 24 silhouette and, optionally, the key groove 34features, the logic may identify a single key blank 24 for use induplicating the master key 24.

Once the proper key blank 24 is identified, the key duplication machine10 may direct output information to the user to indicate which specifickey blank 24 is identified. In one embodiment, such information may bedisplayed on the touch-screen monitor 40. The user may then retrieve theproper key blank 24 from a retail display based on the displayedinformation. In an embodiment, various key blanks 24 may be displayed ona display or retail rack with light indicators positioned near each typeof key blank 24. Once the proper key blank 24 is identified, the machine10 may send a signal to the display rack and the display rack mayilluminate the light indicator associated with the proper key blank 24.Such a system directs the user to the proper key blank 24 and reducesuser error in selecting a key blank 24. The machine 10 may include adisplay connection 59 (as seen in FIG. 3) to connect the machine 10 tothe display rack, through which a signal may be sent from the displayrack from the machine 10. Optionally, the machine 10 and display rackmay be integrated or the machine 10 and rack may be arranged to send andreceive signals remotely, wirelessly, etc. Such apparatus and methodsare described in U.S. patent application Ser. No. 10/633,933, filed onAug. 4, 2003, and titled OBJECT IDENTIFICATION SYSTEM. The Ser. No.10/633,933 application may be incorporated or otherwise utilized withembodiments described herein. The Ser. No. 10/633,933 application iscommonly owned by the present assignee and hereby expressly incorporatedherein by reference in its entirety.

Once the proper key blank 24 is identified and retrieved by the user,the user may remove the master key 24 from the slot 20 in the retentionmechanism panel 21 and place the key blank 24 in the slot 20. When thekey blank 24 is placed into the slot 20, the key blank 24 may bevalidated to insure that the proper key blank was retrieved by the user,internal mechanisms may align the key blank 24, the key blank 24 may befurther secured or clamped, and a key pattern may be cut into the keyblank 24 to duplicate the maser key 22. As previously described, theorientation or registration at which the user inserts the key blank 24in the slot 21 does not affect the subsequent operations on the keyblank 24. The logic may analyze captured images of the inserted blank 24to determine the orientation and adjust all subsequent operationsaccordingly.

FIGS. 8 and 9 illustrate the positioning of a key blank 24 relative tointernal components, mechanisms, and systems as it is initially insertedand secured in the slot 20. In this initial position, the key blank 24is in the imaging zone. The retention mechanism panel 21 is not shown inFIGS. 8 and 9 for clarity. As shown in FIG. 8, a left cutting wheel 60is positioned to the left of the key blank 24 and a right cutting wheel62 is positioned to the right of the key blank 24 as viewed from thefront of the machine 10. A clamping assembly 64, including a top clampmember 66 and a bottom clamp member 68, is located to the left of thekey blank 24 as viewed from the front of the machine 10. The clampingassembly 64 is used to clamp the key blank 24 during cutting, the leftcutting wheel 60 is utilized to cut the left side of the key blank 24,and the right cutting wheel 62 is utilized to cut the right side of thekey blank 24.

The logic may validate that the key blank 24 selected by the user andpositioned in the machine 10 is the proper key blank 24, as previouslyidentified. An image of the key blank 24 may be captured by the opticalimaging device 50, and logic may be used to analyze the image. Suchanalysis may determine or quantify features of the key blank 24 such as,for example, the size and shape of the shoulder 30, the length and widthof the blade 32, whether the blank 24 is designed as a single-sided ordouble-sided key, whether the blade 32 includes any steps, and the like.Such determined features may be compared to data regarding features ofthe previously-identified proper key blank 24 stored in the database.Provided the determined features of the user-selected key blank 24 andthe stored features of the previously-identified proper key blank are inagreement, the logic may determine that the proper key blank 24 wasselected and positioned by the user. The user may be informed that theuser-selected blank 24 is proper, and the duplication process maycontinue. If the determined features of the user-selected key blank 24and stored features of the proper key blank are in not in agreement, thelogic may inform the user that an improper key blank was selected andinstruct the user to reselect a key blank 24 for duplication of themaster key 22. Optionally, the duplication process may be halted untilthe user positions a proper key blank 24, or the machine 10 mayincorporate an override function to allow a key pattern to be cut intothe selected key blank 24.

Prior to clamping the key blank 24 in the clamping assembly 64, the keyblank 24 may be aligned to insure a key pattern is properly cut into theblank 24. The position of the key blank 24, as initially manuallypositioned by the user, may be determined from the captured image of theblank 24. This image is analyzed by logic and compared to the idealposition for cutting the blank 24, and the positioning of the blank 24is adjusted to conform to the ideal cutting position. As best shown inFIGS. 9 and 10, a pair of key positioner fingers 72 and 74 engages thekey blank 24 to align the blank 24. The left positioner finger 72engages the left side of the blade 32, and the right positioner finger74 engages the right side of the blade 24. This engagement squares thekey blank 24 with respect to the X-axis and Y-axis to correct for a userhaving placed the blank 24 into the slot 20 at an angle. The engagementof the fingers 72 and 74 may also properly position the blade 32 alongthe X-axis. If the user did not insert the blank 24 far enough into theslot 20, the fingers 72 and 74 may move the blade 32 along the X-axis tothe proper position. As previously described, the retention mechanism 19secures a blank key 24; however, the force applied to a key 22 and 24 bythe door clamp 14 and base 16 allows the key 22 and 24 to be adjustedrelative to the machine 10.

The left positioner finger 72 is generally fixed with respect to theblank 24. This is to say that forces between the blank 24 and the leftpositioner finger 72 do not cause the left positioner finger 72 todeflect. The right positioner finger 74, however, is designed to deflectslightly upon engagement with the blank 24. The right positioner finger74 includes a cantilever arm 76 that deflects due to forces between theright positioner finger 74 and the blank 24. Such deflection insuresthat sufficient force is applied to the blank 24 by the fingers 72 and74 to grip and align the blank 24. When the fingers 72 and 74 are notneeded, they may be rotated upwards and out of the way. As best shown inFIG. 11, the right positioner finger 74 is mounted onto a shaft 78. Theshaft 78 is arranged to rotate about the X-axis to rotate the finger 74upward and downward as needed. A similar arrangement rotates the leftpositioner finger 72 upward and downward.

Once the positioner fingers 72 and 74 have corrected the alignment ofthe blank 24 based on the analysis of the initial captured image, yetanother image of the blank 24 may be captured to validate that thealignment is now proper. In addition to validating the alignment of theblank 24, this captured image may be utilized to record reference pointsalong the blade 32 such as the location of the key shoulder 30, thelocation of the tip of the blade 32, and the like. As will be furtherdescribed, the logic may use such reference points, along with thedetermination of the orientation of the key blank 24, to guide thecutting wheels 60 and 62 during the cutting process.

Although the alignment of a key is generally described with reference tothe alignment of a key blank 24 upon the insertion of the blank 24 intothe slot 20, it will be readily understood by those skilled in the artthat the positioner fingers 72 and 74 may be used, for example, to aligna master key 22 prior to capturing an image of the key 22 to be analyzedby the logic.

As shown in FIG. 9, once the blank 24 is properly aligned, the clampingassembly 64 may be opened to accommodate the clamping of the blank 24.In an embodiment, the default position of the clamp assembly is open,and the clamp is closed only when clamping a key blank 24. The bottomclamp member 68 is generally fixed, and the top clamp member 66 isarranged to move along the Z-axis. When the clamping assembly 64 isopened, the blank 24 is moved to the left along the Y-axis until theblank 24 is positioned between the top member 66 and bottom member 68clamps. The blank 24 is moved along the X-axis to a specific clampingposition relative to the clamping assembly 64 as determined by the logicfor the specific key blank 24. The logic may specifically position theblank 24 relative to the clamping assembly 64 such that both edges of ablade 32 of a key blank 24 remain exposed for the cutting of a keypattern into both edges of the blade 32. Such an arrangement is commonfor double-sided key blanks.

Such movement of the key blank 24 moves the blank 24 from the imagingzone to the cutting zone. The clamp assembly 64 is generally fixed withrespect to the Y-axis and generally defines the cutting zone. The blank24 is moved along the Y-axis by the synchronized movement of the left 72and right 74 positioner fingers and the retention mechanism panel 21,which includes the slot 20. As seen in FIG. 12, once the blank 24 ispositioned between the top 66 and bottom 68 clamp members, the top clampmember 66 is moved downward along the Z-axis to secure the blank 24 inthe clamp assembly 64. Once the blank 24 is secured in the clampassembly 64, the positioner fingers 72 and 74 are rotated upward aboutthe X-axis and out of engagement with the blank 24. Such movement of thefingers 72 and 74 ensures that the cutting wheels 60 and 62 have accessto the full length of the blade 32 and both edges of the blade 32.

With reference to FIG. 13, the clamping surface of the clamp members 66and 68 are T-shaped. The stem 80 of the T-shaped clamping surface issized such that both the left side and right side of the key blank 24blade 32 is exposed to the cutting wheels 60 and 62 when the blank 24 isclamped in the clamping assembly 64. The bar portion 82 of the T-shapedclamping surface is designed to engage the blank 24 at or above the keyshoulder 30 and above the portion of the blade 32 into which a keypattern is cut. Optionally, the clamping surface may include knurls orother features designed to improve the grip of the clamp members 66 and68 on the blank 24. As best seen in FIG. 12, the top clamp member 66 mayinclude at least one groove 84 designed to allow a top clamp member 66to deflect slightly. Such slight deflections may allow the clampingsurfaces of the clamp members 66 and 68 to adjust for smallirregularities in the surface of the blank 24. For example, the topclamp member 66 may displace slightly so as to accommodate raised logos,words, or numbers stamped or forged into the surface of the blank 24.Such accommodations may reduce or eliminate the chance of point contactbetween the clamping members 66 and 68 and the blank 24 and increase thechances that the clamping force is sufficient to hold the blank 24during the cutting process.

Once the key blank 24 is clamped, the cutting operation can beperformed. The logic may use the quantified and stored information fromthe captured image of the key pattern 36 of the master key 22 tocalculate precise movements of the cutting wheels 60 and 62, withrespect to the key blank 24, to produce a duplicate key. The movementsof the cutting wheels 60 and 62 are generally two-dimensional. Thewheels 60 and 62 are moved along the X-axis to cut the key pattern alongthe length of the blade 32. In addition, the wheels 60 and 62 moveindependently along the Y-axis to cut the depth of each tooth of the keypattern into the blade 32. While numerous paths for the cutting wheels60 and 62 may be utilized, in an embodiment, the cutting wheels 60 and62 begin near the shoulder 30 of the key blank 24 and proceed to the tipof the key blank 24 blade 32 to cut the key pattern into the blade 32.The precise movements calculated for the cutting wheels 60 and 62 may betransferred to a 2-axis CNC cutter so that the key pattern 36 of themaster key 22 may be duplicated on the blade 32 of the key blank 24.

As shown in FIGS. 14 and 15, once the key blank 24 is clamped and thepositioning fingers 72 and 74 are rotated out of the way, the cuttingwheels 60 and 62 may be moved along the Y-axis, into the cutting zone,and into engagement with the blade 32. Typically, the wheels 60 and 62engage the blank 24 near the shoulder 30 of the blank 24. The clampassembly 64 is not shown in FIG. 15 for clarity. As previouslydescribed, the cutting wheels 60 and 62 may move in parallel along theX-axis as the key pattern is cut into the blank 24; however, themovements of each cutting wheel 60 and 62 along the Y-axis areindependent. This independent movement insures that a double-sided keymay be produced quickly and efficiently, with the cutting wheels 60 and62 passing along the length of the blade 32 only once. The rotationalspeed of each cutting wheel 60 and 62 is also independently controlled.In one embodiment, the rotational speed of each cutting wheel 60 and 62is adjusted based on the depth at which the cutting wheel 60 and 62 ismoved into the blade 32 along the Y-axis. For example, in an embodiment,the rotational speed of a cutting wheel 60 and 62 is slowed as the wheel60 and 62 moves deeper into the blade 32 along the Y-axis. In anembodiment, the movement of the wheels 60 and 62 along the X-axis andY-axis are adjusted based on the features of the cut. For example, fordeeper cuts into the blade 24, the movement of the wheels 60 and 62 inthe Y-direction may be slowed, and for shallower cuts, the movement ofthe wheels 60 and 62 in the Y-direction may be increased. Sucharrangements limit wear and service time of the cutting wheels 60 and62.

If the master key 22 is a single-sided key, only one of the cuttingwheels 60 and 62 is engaged with the blank 24 to cut the key pattern 36.The logic may make a determination on whether the left 60 or right 62cutting wheel is to be utilized based on the captured image of the keyblank 24. The user may insert the blank 24 into the slot 20 withoutregard to the orientation of the blade 24. The logic may determine fromthe captured image whether the key pattern should be cut into the leftedge or the right edge of the key blank 24 based on the contour andshape of the shoulder 30 of the blade 32, the tip of the blade 32, orany other characteristic that may distinguish the edges of the blade 32.

Once the key pattern is cut into the key blank 24, the top clamp member66 may be lifted along the Z-axis, releasing the newly-cut key. Thenewly-cut key remains secured by the retention mechanism 19. Thenewly-cut key may be returned to the imaging zone by moving theretention mechanism panel 21 to the right along the Y-axis. A new imageof the newly-cut key may be captured and compared to the captured imageof the master key 22. Logic may utilize such a comparison to validatethat the newly-cut key is within acceptable deviation from the masterkey 22. The deviation of the newly-cut key as compared to the master key22 may be quantified by any statistic method. For example, a number ofmeasurements along the key pattern 36 of the master key and the keypattern of the newly-cut key may be taken and quantified. The averagedifference of the comparable measurements may be used to calculate anaverage difference and compare that average difference to apredetermined limit. The results of such a validation may be displayedto the user on the touch-screen monitor 40 or otherwise output to theuser.

Once the validation is completed, the user may lift the spring-biaseddoor clamp 14 using the handle 18 and remove the newly-cut key from theslot 20. The logic may be arranged to retain the captured image of themaster key 22 for a period of time, such that the user may place anotherproper key blank 24 into the slot 20 and cut yet another duplicate key.If no additional duplicate keys are required, the logic may discard thecaptured image of the master key 22 and prepare to receive anothermaster key 22 and begin the duplication process anew. Such processes maybe driven by the logic with regard to time limits or may be driven bythe user inputting information through a touch screen or other userinterface.

When a newly-cut key is removed from machine, the user may de-burr thekey by inserting the blade of the newly-cut key into the de-burring slot44. As shown in FIGS. 16 and 17, a pair of de-burring brushes 86 may besecured to an interior surface 88 of the shaving drawer 42 and proximateto the de-burring slot 44. The brushes 86 are positioned such that theblade of the newly-cut key engages the brushes as the blade is insertedinto the slot 44. As seen in FIG. 17, the brushes may be square andsecured to an interior surface 88 of the shavings drawer 42 withfasteners 90 such as, for example, a bolt and nut combination. Such afastening arrangement allows for efficient exchanging of de-burringbrushes 86. In addition, the square shape of the brushes 86 allows thebrushes 86 to be rotated or flipped as one side of a brush 86 becomesworn due to repeated use, thus increasing the service life of a brush86. Such an arrangement may provide for sixteen unique positions for thepair of brushes 86.

As described above, the process of cutting duplicate keys relies on themovement of numerous interior components, mechanisms, and systems. Suchmovement is generally facilitated through a number of motors mountedwithin the key duplication machine 10. FIGS. 18 and 19 illustrate theinterior of the machine 10 as viewed from the rear of the machine 10. Asshown in FIGS. 18 and 19, the key duplication machine 10 includes nineindependent motors to facilitate movement within the machine 10.

A retention mechanism slide motor 92 is coupled to the retentionmechanism panel 21 to move the retention mechanism panel 21 along theY-axis. Such movement occurs as a key blank 24 is moved between theimaging zone and the cutting zone.

A first slide motor 94 is coupled to both the right cutting wheel 62 andthe right positioner finger 74 to move the right cutting wheel 62 andthe right positioner finger 74 along the Y-axis. A second slide motor 96is coupled to both the left cutting wheel 60 and the left positionerfinger 72 to move the left cutting wheel 60 and the left positionerfinger 72 along the Y-axis. Such movement of the positioner fingers 72and 74 and the cutting wheels 60 and 62 occur under a number ofconditions. For example, when the fingers 72 and 74 are engaged with theblade 32 of a key blank 24, movement of the fingers 72 and 74 along theY-axis may move the blank 24 between the imaging zone and the cuttingzone. In another example, when a key blank 24 is secured in the clampingassembly 64 and the fingers 72 and 74 are rotated out of engagement withthe blade 32, the cutting wheels 60 and 62 may be independently movedalong the Y-axis to facilitate the cutting of the key pattern 36 intothe blade 32.

A third slide motor 97 is coupled to both the left 60 and right 62cutting wheels to move the cutting wheels 60 and 62 together along theX-axis. Such movement along the X-axis occurs as the wheels 60 and 62move along the length of the blade 32 to cut the key pattern 36 into theblade.

A first rotational motor 98 is coupled to the right cutting wheel 62 torotate the right cutting wheel 62 about the X-axis as the wheel 62 cutsa key pattern 36 into the right edge of a key blank 24 blade 32. Asecond rotational motor 100 is coupled to the left cutting wheel 60 torotate the left cutting wheel 60 about the X-axis as the wheel 60 cuts akey pattern 36 into the left edge of a key blank 24 blade 32.

A third rotational motor 102 is coupled to the right positional finger74 to rotate the finger 74 about the X-axis to engage and disengage thefinger 74 with the blade 32 of the key blank 24. A fourth rotationalmotor 104 is coupled to the left positional finger 72 to rotate thefinger 72 about the X-axis to engage and disengage the finger 72 withthe blade 32 of the key blank 24.

A clamp motor 106 is coupled to the top clamp member 66 to move the topclamp member 66 along the Z-axis. Such movement clamps and unclamps akey blank 24 in the clamp assembly 64 prior to and after the cutting ofkey patterns 36 into the blade 32 of a blank 24.

The key duplication machine 10 as described herein may be designed andfabricated as an assembly of modular components. In an embodiment, asshown in FIGS. 20 and 21, the machine 10 may be assembled from fivemodular components. Such modular components may include a base module110, a front panel module 112, a hood module 114, a computer module 116,and a support plate module 118. The base module 110 supports the machine10 and may provide structural support for the mounting or holding ofcomponents such as, for example, the shavings drawer 42 and the lightingpanel 52. The front panel module 112 may provide structural support forthe mounting or holding of components such as, for example, the doorclamp 14, base 16, handle 18, retention mechanism panel 21, andretention mechanism slide motor 92. The hood module 114 may providestructural support for the mounting or holding of components such as,for example, the monitor 40, wiring chassis, and power supplies. Thecomputer module 116 may provide structural support for the mounting orholding of components such as, for example, a hard drive, a centralprocessing unit, circuit boards, logic units, and other such computerrelated components. The support plate module 118 may provide structuralsupport for the mounting or holding of internal components of themachine 10. For example, the support plate module 118 may support anumber of motors, such as the rotational motors 98, 100, 102, and 104for rotating the cutting wheels 60 and 62 and positioner fingers 72 and74; slide motors for positioning the wheels and positioner fingers 94,96, and 97; and the clamp motor 106. In addition, the support platemodule 118 may support components such as the optical imaging device 50,reflector plate 54, the cutting wheels 60 and 62, positioner fingers 72and 74, etc. Such modular design and assembly increases the ease ofmanufacture, assembly, and maintenance of a key duplication machine 10.

The process of duplicating a key using the key duplication machine 10 asdescribed above may be facilitated through the interaction of a userwith a user interface. For example, the user may be given a number ofoptional methods for identifying a proper key blank for the duplicationof a master key. Such options may be displayed on a user interface suchas, for example, a touch-screen monitor. Once displayed on atouch-screen monitor, the user may initiate the duplication process bymanually selecting one of the offered options. A first option mayrequest that the key duplication machine determine the proper key blankby taking a photograph of the master key, as described herein, andcomparing the physical characteristics of the master key to a databasecontaining physical characteristics of key blanks. The results of such acomparison may yield more than one potentially appropriate key blank. Asillustrated in FIG. 22, the user interface may graphically display twoor more key blanks that may be used to duplicate the master key. Theuser may select the preferred key blank by touching a graphicrepresentation of one of the key blanks 200 and 202. Alternatively, theuser may select a graphic 204 indicating the user intends to insertanother master key into the machine.

Another option for identifying a proper key blank for the duplication ofa master key is for a user to provide specific known informationregarding the master key. As shown in FIG. 23, the user may enterspecific information regarding a master key through a touch-screenmonitor. The user may select specific information regarding a key from adynamically populated selection box 206. The user may utilize theselection box to provide information such as the category of the key(automobile, house, padlock, etc.), the use, the make, the model oflock, the year lock was manufactured, the name of the manufacturer, orthe part number of key or lock. The user may toggle the informationdisplayed in the selection box 206 by touching buttons 208 associatedwith the different types of information. The user may select informationfor the selection box 206 by simply touching the correct information inthe selection box 206.

FIG. 24 illustrates a user interface directed specifically to automobilekeys. The user may enter specific information regarding an automobilemaster key to identify the proper key blank. The user may selectinformation such as automobile make, model, and model year from adynamically populated selection box 210. The information in theselection box 210 may be toggled by touching an automobile make button212, an automobile model button 214, and a model year button 216.

In each of the options described above, specific information entered bythe user may be compared to a database containing information regardingkey blanks. Such a comparison may be used to identify the proper keyblank. Once the proper key blank is identified, the key blank may bedisplayed on the user interface to inform the user which key blankshould be retrieved by the user.

Regardless of the method used to identify a key blank, the machine maybe arranged to warn a user that a master key to be copied may contain acomputer chip, transponder, or the like. Such computer chips andtransponders are common in automobile keys. Duplicates for such keys mayneed to include a corresponding computer chip in order for the duplicateto be successful. Once it is determined that a master key may have acomputer chip, the user may be instructed to place the master key in ornear a device designed to sense the presence of a computer chip in akey. If the master key does include a computer chip, the user may beinstructed on how to proceed to ensure a functional duplicate key ismade.

Once a proper key blank is identified and retrieved by the user, theuser interface may further guide the user in duplicating the master keyand displaying the progress of duplication of the key. As shown in FIG.25, a list of actions 218 may be displayed on the user interface. Thefirst action shown instructs the user to load a key blank. The user mayremove the master key and insert the proper key blank and press a box220 to initiate the key duplication process. The key duplication machine10 may then proceed with additional actions such as scanning the blankand verifying the proper blank is loaded, positioning the key blank toinsure proper alignment, cutting the key blank, etc. As shown in FIG.26, as actions are completed, checks may be displayed in boxes 222 toindicate that an action has been completed. The user interface may alsoinclude a graphic to terminate the cutting process. For example, a usermay touch a graphic of a stop sign 224 to stop the cutting process.

The logic may be arranged to collect and store data regarding keyduplications performed by the key duplication machine 10. For example,data regarding the number of key duplications performed, the number ofdifferent key blanks used in key duplication, the number of anindividual key blank used in key duplication, success rate ofduplicating keys, and the like may be collected and stored. Suchinformation and data may be analyzed by the logic associated with themachine 10 or be downloaded for remote analysis.

In an embodiment, components, such as motors, may be eliminated from thedoor panel 21 design. As illustrated in FIGS. 27-31, the door panel 21may include a slot 310. The slot 310 may be sized and shaped to receivea key therethrough. The slot may be generally centered with respect tothe optical imaging device 50.

The door panel 21 may include a pair of free floating grippers 312, 314configured to grip the key as it is inserted into the slot 310. Theupper gripper 312 and lower gripper 314 may be each supported by one ormore springs 316. As shown in the figures, each gripper 312, 314 mayinclude springs positioned on both sides. The springs 316 may bias thegrippers 312, 314 toward each other to a closed position. The springs316 may provide sufficient force to hold the key in place while stillallowing the key to be moved when sufficient force is placed on it by auser or other machine components.

The upper and lower grippers 312, 314 may include respective upper andlower tapered portion 318, 319 formed in the surface of each grippers312, 314, as shown in FIGS. 29 and 30. The tapered surfaces 318, 319 maybe aligned with one another and may assist in opening the grippers 312,314 when a key is inserted between them. The tapered portions 318, 319may further be aligned with the imaging device 50 to assist withaligning the key with the imaging device 50.

The upper and lower grippers 312, 314 may further each includerespective ledges 321, 323 formed along the surface of each grippers312, 314. The ledges 321, 323 may comprise a flat surface along aportion of the gripper that abuts the opposing gripper. The ledges 321,323 may be configured to hold a key level when inserted between thegrippers 312, 314. The ledges 321, 323 may further allow for rotationaland lateral sliding movement of the key between the grippers 312, 314.

The upper and lower grippers 312, 314 may be configured to accommodate afixed wall 320 on a first side and a movable wall 322 on a second sideopposite the first side. The fixed wall 320 may prevent lateral movementof a key inserted between the grippers 312, 314 in the direction towardthe fixed wall 320. The fixed wall 320 and moveable wall 322 may belocated in front of the ledges 321, 323 and may assist in holding thekey in position while still allowing lateral movement of the key. Itwill be appreciated that instead of one fixed wall 320 and one movablewall, the door panel 21 may instead comprise two fixed walls. It will befurther appreciated that the fixed wall 320 may be movable in a firstdirection, such as the vertical direction, while being generally fixedin all other directions, such as the horizontal direction.

The moveable wall 322 may be biased toward the fixed wall 320. Forexample, a spring 324 may be connected to the movable wall to bias thewall 322 toward the fixed wall 320. The spring 324 may be connected tothe movable wall 322 at a notch 328 in the wall. The spring 324 may bearranged to bias the movable wall 322 only up to a specified position inorder to maintain a space between the movable wall 322 and the fixedwall 320. The space may allow for insertion of a key into the slot 310between the walls 320, 322.

In an embodiment, the movable wall 322 may be fixed at a single pivotpoint 326. The pivot point 326 may allow the movable wall 322 to swingor pivot from a single point. The pivot point 326 may be located farenough away from the slot that the motion of the movable wall 322 withinthe slot 310 may resemble lateral movement rather than pivotal orcircular movement. It will be appreciated that biasing of the movablewall 322 is not limited to a pivot design or spring biased design butmay include any appropriate biasing mechanism or device may arranged touse other biasing techniques, including gravity based on the weight ofthe movable wall 322.

In use, a key may be aligned with the tapered portions 318, 319 andinserted into the slot 310 through the grippers 312, 314. The grippers312, 314 may apply pressure on the key to assist in holding the key inposition. The key may rest on the lower gripper 314 while the uppergripper 312 applies pressure on the key. The walls 320, 322 may assistwith lateral and insertion depth alignment of the key as it is insertedthrough the grippers 312, 314. The movable wall 322 may allow forsignificant lateral movement of the key within the grippers 312, 314when needed. The movable wall may pivot about the pivot point 326 toallow for such lateral movement of the key.

In an embodiment, the positioners 72, 74 may be configured to facilitatelateral movement of a key from the imaging position to a cut position,and from cut position to imaging position. It will be appreciated,however, that such use of the positioner fingers presents numerouschallenges. For example, when moving a cut key, at least one side of thekey may include bittings and cuts that yield a surface that is not flat.Such bittings and cuts may vary greatly from key to key. Engagementbetween the positioners 72, 74 and the key at a non-flat surface mayresult in undesirable movement, such as pivoting of the key about thecontact point. Therefore, the positioners 72, 74 must be configured tostrategically engage the key at a select location along the bittings.

The imaging device 50 may be configured to analyze the bittings todetermine the best location for the positioners 72, 74 to engage.Specifically, the bittings may be analyzed from the end of the key bladeto the shoulder along the length of potential travel of the positioners.The optimum location for engaging the key may then be determined usingone of the three scenarios described below.

In a first scenario, a positioner may include a pointed finger having arounded end to engage the bittings, such as the positioner 74illustrated in FIG. 10. The bittings may be analyzed to find the idealbitting valley and the positioner 74 may be arranged such that thefinger engages the valley. The ideal valley may be the deepest valley ormay be the first reachable valley that is close to the head of the key.The two positioners may then compress they key with enough force to gripthe key for lateral movement. The force may be modified or reduced ifthe positioner 74 cannot reach the bottom of the valley.

In a second scenario, a flat and wide positioner may engage thebittings, such as the positioner 72 illustrated in FIG. 10. The bittingsmay be analyzed to find the two optimal peaks that the positioner 72 maysimultaneously engage to provide the best possible alignment of the key.When selecting the two optimum peaks, many factors may be considered.The difference between the height of the peaks may be considered, in anattempt to minimize the rotational angle of the key when gripped. Thespread of the peaks may be considered to reduce the chance that thepositioner 72 slips and disengages from one or both peaks. The degree towhich the positioner may be centered with respect to the two peakswithout touching other portions of the blade may be considered. Peaksthat are reasonably flat may be considered an optimum point at any pointalong the flat peak. Using these criteria, the optimum two peaks may bedetermined and the positioner 72 may be aligned with the peaks. The twopositioners may then compress the key with enough force to grip the keywhile accounting for the difference in the peak heights.

In a third scenario, a double sided key with bittings cut on both sidesmay be gripped by a flat positioner 72 and a positioner with a pointedfinger 74. The flat positioner may engage two peaks of the bittings asdescribed above in the second scenario. The second positioner 74 maythen either be centered with respect to the flat positioner 72 or may becentered on a valley that is closest to the flat positioner 72 in orderto prevent rocking and pivoting of the key. The positioners may then becompressed and grip the key. The force may be modified or reduced if thepositioner 74 cannot reach the bottom of the valley or other featurethat it touches.

We claim:
 1. A key duplicating machine comprising: a front panel havinga slot to receive a key therein, said slot comprising: a first sidewall; and a second side wall, wherein said second side wall is movablewith respect to said first side wall; a sensing device configured tocapture data related to a master key; and a cutting member configured tocut a key pattern into a key blank.
 2. The machine of claim 1, whereinsaid second wall is configured to pivot about a pivot point.
 3. Themachine of claim 1, wherein said second wall is biased toward said firstside wall.
 4. The machine of claim 1 further comprising a lower gripperand an upper gripper configured to grip a key when it is held in saidslot.
 5. The machine of claim 4, wherein said lower gripper ispositioned below said upper gripper and biased toward said uppergripper.
 6. The machine of claim 4, wherein said upper gripper ispositioned above said lower gripper and biased toward said lowergripper.
 7. The machine of claim 4, wherein said front panel includes afront side and a rear side opposite said front side, wherein said panelis configured to receive a key in said slot from said front side, andwherein said lower gripper and said upper gripper are located on saidrear side.
 8. The machine of claim 4 wherein, said lower gripperincludes a tapered portion.
 9. The machine of claim 8, wherein saidupper gripper includes a tapered portion.
 10. The machine of claim 9,wherein said upper ledge and said lower ledge each include a ledgeadjacent to said tapered portions.
 11. The machine of claim 1, whereinsaid first side wall is movable with respect to said second side wall.12. A key duplicating machine comprising: an opening in said machine toreceive a key therein; a sensing device configured to capture datarelated to a key inserted into said opening; a cutting member configuredto cut a key pattern into a key blank; a positioning mechanismconfigured to move a key from a first position to a second position; anda logic configured to analyze said data to determine a position forengaging said positioning mechanism with said key.
 13. The machine ofclaim 12, wherein said positioning mechanism includes a firstpositioning finger and a second positioning finger.
 14. The machine ofclaim 12, wherein said logic is configured to determine whether said keyhas bittings cut into the key blade on one side of the key blade or twosides of the key blade.
 15. The machine of claim 12, wherein saidposition determined by said logic is a valley on a bittings of said key.16. The machine of claim 15, wherein said positioning mechanism includesa positioner with a pointed finger to engage said bittings.
 17. Themachine of claim 12, wherein said position determined by said logic istwo raised points on a bittings of said key
 18. The machine of claim 17,wherein said positioning mechanism includes a positioner with a flatedge to engage said bittings.
 19. The machine of claim 12, wherein saidsensing device includes an imaging device.
 20. The machine of claim 19,wherein said data related to said key includes image data.